The Gaggia element pin is 0.08" and there is a friction/push-on connector. I am not sure of the technical name for that type of connector and did not find them. I did my own PID wiring and had some Spade connectors. Picture is worth 1000 words, so the pictures below. One shows 2 6.2mm/1/4" spades. The L one is for 22 - 18 awg, and the R for 16 - 14 awg. The 14 awg end was opened a little so that the 22 awg end nestles inside.

You might contact one of the repair places and find a connector made for what you are trying. Many brands of elements have slide on connectors and one should be the same diameter. I already have all of the parts and shrink wrap to make my own.

Obviously all is at your own risk as it will not be OEM, but what you have now is also probably some long term connection and insulation risk.

The next photo shows assembly with a 0.08" drill bit inserted, simulating the Gaggia element top. The drill bit was a little too large and that side of the spade also opened for a snug fit. If I were doing this, I would put a R angle bend in one spade between the spade end and the wire end to simulate the Silvia configuration, then solder the joint, then shrink wrap to insulate. Those spades come ready to solder, so very easy, but make the bend first. If you fit the drill end snuggly, but not too much pressure, then you get a great almost full circumference fit. Too loose and you get poor connection and too tight and you fight to get it on, and perhaps loosen the insulation around the element. Again, your own risk.

Post when you are done, curious to see if it works. I am not sure of the size of your terminal post, so if it is larger, you may need a larger spade. Larger on the terminal side may be easier/better any way. I believe the match to the one left on the wire will be 1/4" male. Measure the post and take a matching drill to the electronic store to check size. The 3/8" female 12 - 10 awg.

just as a follow up, the post measures .136, i will have to have a search for something to fit around that.. thanks for all your help.. anyone else that has any info, i would much appreciate it.. does anyone know what type of welding that would be to tack the connection to the post?

Well knowing the size of the post, how about MacGyver Fix 2! This literally took about 5 minutes, not soldered, but add only a couple minutes. I had 1/8" ID brass tubing, obviously not sufficient for 0.136", but a tight fit is needed. I spiral cut the tubing about 1 revolution in 1/2" and then cut it about another 1/8 -3/16" longer, total about 5/8" long. With the spiral cut, the 1/8" is on 0.136" drill end firmly screwed on. In the uncut end is a spade connector for the existing wire spade. I would bend it over to 90 degrees and solder in the end and screw it on the post.

Tool was a Dremel with the fiber cutting wheel.

It took longer to type this up than to make it. I did not even clean and debut the spiral cut, but it works. 1/8" ID tubing also comes as copper which is softer. Probably a better conductor, but not the grip on the post. Of course the pjoorest connection may be the spade because of contact and surface, but the spade is used in OEM.

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